La voie hydrométallugique représente une alternative pour la récupération des métaux de valeur tels que le nickel et le cobalt contenus dans les batteries Li-ion usagées. La première étape du procédé hydrométallurgique, l'étape de lixiviation a été optimisée grâce à l'étude du comportement du matériau actif d'électrode positive LiNi1/3Mn1/3Co1/3O2 (NMC) qui s'avère être le candidat idéal pour les batteries de véhicules électriques. Tout d'abord, l'étude des aspects thermodynamiques de la réaction de dissolution a permis de prédire le comportement du NMC dans divers acides. Puis, l'approche cinétique a conduit à l'élucidation du mécanisme se produisant lors de l'étape de lixiviation et à la mise en évidence de l'étape cinétiquement déterminante de la dissolution. Ce mécanisme a par la suite été généralisé aux autres matériaux couramment rencontrés dans les batteries Li-ion. L'impact d'agents réducteurs minéraux, organiques et métalliques pour promouvoir la dissolution du NMC a été évalué. Cette approche compare l'effet de réactifs à faible (acides sulfurique et chlorhydrique) et fort (acides citrique, oxalique et formique et peroxyde d'hydrogène) pouvoir réducteur ainsi que celui du cuivre et de l'aluminium provenant des collecteurs de courants des batteries Li-ion. Cette étude soulève le fort intérêt de l'emploi des collecteurs de courant présents de manière inhérente dans la fraction traitée par hydrométallurgie. / Basic hydrometallurgical routes represent an alternative to recover valuable metals such as nickel and cobalt from spent Li-ion batteries. The first step of hydrometallurgical process, lixiviation step is optimized by studying the behaviour of LiNi1/3Mn1/3Co1/3O2 (NMC) positive electrode active material, due to its good performances which make it an adequate candidate for the electric vehicles. First of all, the study of thermodynamic aspects allows predicting the behaviour of NMC material in various acidic media. Then, the kinetic approach leads to define the mechanism occurring during the leaching step and to outline the rate-limiting step of the dissolution. The reductive effect of mineral, organic and metallic reducing agents to promote leaching of NMC material is evaluated. The approach comparatively evaluates the reducing power impact of weak (sulfuric and hydrochloric acids), strong reducing agents (citric, oxalic and formic acids and hydrogen peroxide) and copper and aluminum from Li-ion batteries current collectors. This work points out the strong interest to advantageously use current collectors inherently present in the fraction treated by hydrometallurgy.

Les accumulateurs Li-ion sont des systèmes de stockage électrochimique de l’énergie composés de deux électrodes, dans lesquelles les ions Li+ vont venir s’insérer réversiblement lors des cycles de charge et de décharge. Afin d’intégrer le domaine des véhicules électriques, leur densité d’énergie doit être augmentée pour apporter l’autonomie demandée. Ceci peut être réalisé en augmentant la d.d.p. entre les deux électrodes. Nous visons ici la synthèse de nouveaux matériaux polyanioniques d’électrode positive dans lesquels le lithium pourrait venir s’insérer à haut potentiel en faisant intervenir le couple Cu3+/Cu2+ (5,3 V vs Li+/Li). Parmi les phosphates de cuivre synthétisés, Li2CuP2O7 présente une oxydation non réversible à haut potentiel (> 5 V). Sa synthèse à basse température permet d’exacerber les réactions, en raison de la faible taille des particules obtenues ainsi que de la présence de carbone conducteur à leur surface, mais la phase s’avère instable à haut potentiel.En ce qui concerne les composés de type sulfate, une nouvelle phase Li4Cu4O2(SO4)4 est isolée, montrant une insertion réversible du lithium à une valeur moyenne de 4,7 V. Cependant, la capacité de ce matériau est très faible (15 mAh.g-1) et plusieurs substitutions chimiques avec du fluor, du magnésium ou du sodium sont étudiées dans le but d’augmenter la mobilité du lithium. / Li-ion batteries (LIBs) are energy storing electrochemical devices composed of two electrodes, in which Li+ ions are reversibly inserted during charge and discharge cycles. Their use in electric vehicles relies on the increase of their energy density, to provide enough autonomy. This can be reached by increasing the cell d.d.p. We thus aim the synthesis of new positive electrode polyanionic materials, in which lithium could be inserted at high potential, using the Cu3+/Cu2+ couple’s activity (5,3 V vs Li+/Li). Among the synthesized copper phosphates, Li2CuP2O7 presents a non-reversible oxidation at high potential (>5 V). Its low temperature synthesis intensifies the reaction, due to the smaller particle size achieved as well as the presence of a conductive carbon coating, but the phase is instable at high potential. Concerning sulfate-type compounds, a new phase Li4Cu4O2(SO4)4 is isolated, showing a reversible lithium insertion at an average value of 4.7 V. Nevertheless, its capacity is very low (15 mAh.g-1) and various chemical substitutions with fluorine, magnesium or sodium are attempted to increase lithium’s mobility.

This work deals with electrolytes and ionic liquids for Li-ion batteries. Following interaction of electrolytes and ionic liquids to electrodes material. In the theoretical part attention is focused on the description of battery electrolytes and ionic liquids for lithium-ion batteries.

This diploma thesis is concerned with topic of lithium-ion batteries recycling. In this document the particular methods containing commercial used recycling processes or only laboratory used processes are discussed. Because rising amount of spent Li-ion accumulators is necessary find proper methods to recycle this type of accumulators. Also legislation question of this issue is important. In practical part is described procedure and results performed recycling method.

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Les batteries lithium-ion s'affichent comme de bons candidats pour assurer le stockage réversible de l'énergie électrique sous forme électrochimique. Toutefois, elles sont à l'origine d'un certain nombre d'incidents aux conséquences plus ou moins dramatiques. Ces incidents sont souvent liés au phénomène d'emballement thermique. La sécurité des batteries Li-ion représente par conséquent un enjeu technique et sociétal très important. C'est dans ce contexte que vient s'inscrire ce travail de thèse dans le cadre d'une collaboration entre IFPEN, l'INERIS et le LISE. Une double approche de modélisation et expérimentation a été retenue. Un modèle 3D du comportement thermique a été développé à l'échelle de la cellule, couplant les phénomènes thermiques et chimiques, et prenant en compte le vieillissement par croissance de la SEI sur l'électrode négative. Le modèle a été calibré pour la chimie LFP/C sur deux technologies A123s (2,3 Ah) et LifeBatt (15 Ah), puis validé expérimentalement. Le modèle permet d'identifier les paramètres critiques d'emballement de cellules, il permet également de discuter l'effet du vieillissement sur l'emballement thermique. Grâce à l'expérimentation, les connaissances en termes d'amorçage et de déroulement d'un emballement thermique d'une batterie Li-ion, ont pu être enrichies, en particulier pour les cellules commerciales LFP/C cylindriques A123s, LifeBatt, et pour les cellules NMC/C prismatiques en sachet souple PurePower (30 Ah). Cette étude ouvre de nouvelles possibilités pour améliorer la prédiction des différents événements qui ont lieu lors de l'emballement thermique des batteries Li-ion, à différentes échelles. / Li-ion secondary batteries are currently the preferred solution to store energy since a decade for stationary applications or electrical traction. However, because of their safety issues, Li-ion batteries are still considered as a critical part. Thermal runaway has been identified as a major concern with Li-ion battery safety. In this context, IFPEN, INERIS and LISE launched a collaboration to promote a PhD thesis so called « understanding and modeling of thermal runaway events pertaining to new and aged Li-ion batteries ». To achieve this goal, a double approach with modeling and experimental investigation is used. A 3D thermal runaway model is developed at cell level, coupling thermal and chemical phenomena, and taking into account the growth of the SEI layer as main ageing mechanism on negative electrode. Advanced knowledge of cells thermal behavior in over-heated conditions is obtained particularly for commercial LFP / C cylindrical cells: A123s (2,3Ah), LifeBatt (15Ah), and NMC / C pouch cells: PurePower (30 Ah). The model was calibrated for LFP / C cells, and then it was validated with thermal abuse tests on A123s and LifeBatt cells. This model is helpful to study the influence of cell geometry, external conditions, and even ageing on the thermal runaway initiation and propagation. This study opens up new possibilities for improving the prediction of various events taking place during Li-ion batteries thermal runaway, at various scales for further practical applications for safety management of LIBs.

This diploma thesis deals with description of the principle of Li-ion cells, literature search on the topic of mathematical models of Li-ion cells and the creation of a selected mathematical model in MATLAB, which is able to simulate the course of voltage and state of charge as a function of time for different ambient conditions, such as various aging of battery .The creation of both the model and the procedure of identification of parameters necessary for the creation of the model are described here as well as different options of identification of parameters. The selected Thevenin model is then compared with the real course and the accuracy of the model is evaluated with respect to the measured course.

Lithium-ion batteries (LIBs) are receiving significant attention from both academia and industry as one of the most promising energy storage and conservation devices due to their high energy density and excellent safety. Graphite, the most widely used anode material, with limitations on energy density, can no longer satisfy the requirements proposed by new applications. Therefore, further improvement on the electrochemical performance of anodes has been long pursued, along with the development of new anode materials. Among potential candidates, Si and Sn based anodes are believed to be the most promising. However, the dramatic volume expansion upon Li-intercalation and contraction upon Li de-intercalation cause mechanical instability, and thus cracking of the electrodes. To overcome this issue, many strategies have been explored. Among them the most efficient strategies include introduction of a nanostructure, coupled with a buffering matrix and coating with a protective film. However, although cycling life has been significantly increased using these three strategies, the capacity retention still needs improvement, especially over extensive charge-discharge cycles. In addition, more efforts are still needed to develop new fabrication methods with low costs and high efficiency. To further improve mechanical stability of electrodes, understanding of the failure mechanisms, particularly, the failure mechanisms of Si and Sn nanomaterials is essential. Therefore, some of the key factors including materials fabrication and microstructural changes during cycling are studied in this work. Hollow Si nanospheres have proved to be have a superior electrochemical performance when applied as anode materials. However, most of fabrication methods either involve use of processing methods with low throughput, or expensive temporary templates, which severely prohibits large-scale use of hollow Si spheres. This work designed a new template-free chemical synthesis method with high throughput and simple procedures to fabricate Si hollow spheres with a nanoporous surface. The characterization results showed good crystallinity and a uniform hollow sphere structure. The substructure of pores on the surface provides pathways for electrolyte diffusion and can alleviate the damage by the volume expansion during lithiation. The success of this synthesis method provides valuable inspiration for developing industrial manufacturing method of hollow Si spheres.3D graphene is the most promising matrix that can provide the necessary mechanical support to Sn and Si nanoparticles during lithiation. 2D graphene, however, results in Sn/graphene nanocomposites with a continuous capacity fade during cycling. It is anticipated that this is due to microstructural changes of Sn, however, no studies have been performed to examine the morphology of such cycled anodes. Hence, a new Sn/2D graphene nanocomposite was fabricated via a simple chemical synthesis, in which Sn nanoparticles (20-200 nm) were attached onto the graphene surface. The content of Sn was 10 wt.% and 20 wt.%. These nanopowders were cycled against pure Li-metal and, as in previous studies, a significant capacity decrease occurred during the first several cycles. Transmission and scanning electron microscopy revealed that during long term cycling electrochemical coarsening took place, which resulted in an increased Sn particle size of over 200 nm, which could form clusters that were 1 m. Such clusters result in a poor electrochemical performance since it is difficult for complete lithiation of the Sn to occur. It is hence concluded that the inability of Sn/2D graphene anodes to retain high capacities is due to coarsening that occurs during cycling. In addition to using forms of carbon to buffer the Sn expansion, it has been proposed to alloy Sn with S, which has a low redox potential vs Li⁰/Li⁺. Therefore, another new anode proposed here is that of SnS attached to graphite. The as prepared powders had a flower-like structure of the SnS alloy. Electrochemical cycling and subsequent microstructural analysis showed that after electrochemical cycling this pattern was destroyed and replaced by Sn and SnS nanoparticles. Based on the electron microscopy and XRD analysis, it was concluded that selective leaching of S occurs during lithiation of SnS particles, which results into nano SnS and Sn particles to be distributed throughout the electrolyte or SEI layer, without being able to take part in the electrochemical reactions. This mechanism has not been noted before for SnS anodes and indicates that it may not be possible to retain the initial morphology of SnS alloy during cycling, or the ability of SnS to be active throughout long term cycling. To conclude it should be stated that the goal and novelty of this thesis was (i) the fabrication of new Si, Sn/graphene and SnS/C nanostructures that can be used as anodes in Li-ion batteries and (ii) the documentation of the mechanisms that disrupt the initial structural stability of Sn/2D graphene and SnS/C anodes and result in severe capacity loss during long term cycling (over 100 cycles). These systems are of high interest to the electrochemistry community and battery developers.

Developing a sustainable energy infrastructure for the 21st century requires the large scale development of renewable energy resources. Fully exploiting these inherently intermittent supplies will require advanced energy storage technologies, with rechargeable Li-ion and Na-ion batteries considered highly promising for both vehicle electrification and grid storage applications. However, the performance required of battery materials has not been achieved, and significant improvements are needed. Modern computational techniques allow the elucidation of structure-property relationships at the atomic level and are valuable tools in providing fundamental insights into novel materials. Therefore, in this thesis a combination of atomistic simulation and ab initio density functional theory (DFT) techniques have been used to study a number of potential battery cathode materials. Firstly, Na2FePO4F and NaFePO4 are interesting materials that have been reported recently as attractive positive electrodes for Na-ion batteries. Here, we report their Na-ion conduction behaviour and intrinsic defect properties using atomistic simulation methods. Na+ ion conduction in Na2FePO4F is predicted to be two-dimensional (2D) in the interlayer plane. Na ion migration in NaFePO4 is restricted to the [010] direction along a curved trajectory, leading to quasi-1D Na+ diffusion. Furthermore, Na/Fe antisite defects are predicted to have a lower formation energy in NaFePO4 than Na2FePO4F. The higher probability of tunnel occupation with a relatively immobile Fe2+ cation - along with a greater volume change on redox cycling - contributes to the poor electrochemical performance of NaFePO4. Secondly, work on the Na2FePO4F system is extended to include investigation of the surface structures and energetics. The equilibrium morphology is found to be essentially octagonal, compressed slightly along the [010] direction, and is dominated by the (010), (021), (122) and (110) surfaces. The calculated growth morphology is a more ``rod-like'' nanoparticle, with the (021), (023), (110) and (112) planes predominant. The (010) surface lies parallel to the Na layers in the ac plane and is unlikely to facilitate Na+ intercalation. As such, its prominence in the equilibrium morphology, and absence from the growth morphology, suggests nanoparticles synthesised in a kinetically limited regime should provide higher rate performance than those synthesised in close to equilibrium conditions. Surface redox potentials for Na2FePO4F derived using DFT vary between 2.76 - 3.37 V, in comparison to a calculated bulk cell voltage of 2.91 V. Most significantly, the lowest energy potentials are found for the (130) and (001) planes suggesting that upon charging Na+ will first be extracted from these surfaces, and inserted lastly upon discharging. Thirdly, the mixed phosphates Na4M3(PO4)2P2O7 (M=Fe, Mn, Co, Ni) are explored as a fascinating new class of materials reported to be attractive Na-ion cathodes, displaying low volume changes upon cycling indicative of long lifetime operation. Key issues surrounding intrinsic defects, Na-ion migration mechanisms and voltage trends have been investigated through a combination of atomistic energy minimisation, molecular dynamics and DFT simulations. The MD results suggest Na+ diffusion extends across a 3D network of migration pathways with an activation barrier of 0.20-0.24 eV, and diffusion coefficients (DNa) of 10-10-10-11 cm2s-1 at 325 K, suggesting high rate capability. The cell voltage trends, explored using DFT methods, indicate that doping the Fe-based cathode with Ni can significantly increase the voltage, and hence energy density. Finally, DFT simulations of K+-stabilised α-MnO2 have been combined with aberration corrected-STEM techniques to study the surface energetics, particle morphologies and growth mechanism. α-K0.25MnO2 grown through a hydrothermal synthesis method is found to produce primary nanowires with preferential growth along the [001] direction. Primary nanowires attach through a shared (110) interface to form larger secondary nanowires. This is in agreement with DFT simulations with the {100}, {110} and {211} surfaces displaying the lowest surface energies. The ranking of surface energies is driven by Mn coordination environments and surface relaxation. The calculated equilibrium morphology of α-K0.25MnO2 is consistent with the observed primary nanowires from high resolution electron microscopy images.

A key metric that affects Li-ion battery cell performance is the electronic conductivity of the electrode films. Previous research has found that the conductivity of electrodes is not homogeneous throughout the entirety of the deposited film area. To further characterize the non-homogeneity of the conductivity of electrode films, a micro-N-line probe and a micro-flex-line probe were developed to take micro-scale conductivity measurements of thin-film battery electrodes in a non-destructive manner. These devices have been validated by comparing test results to those of it's predecessor, the micro-four-line probe, on various commercial-quality Li-ion battery electrodes. Results show that there is significant variation in conductivity on a millimeter and even micrometer length scale throughout the electrode film. Compared to the micro-four-line probe, the micro-N-line probe and micro-flex-line probe perform six times as many measurement configurations made on contact with the electrode, while providing a more robust design. Design improvements on the micro-four-line probe in order to fabricate the micro-flex-line probe are the main focus of this thesis. Researchers and manufacturers can use this probe to identify heterogeneity in their electrodes during the fabrication process, which will lead to the development of better batteries.